Warehouse operations are continually looking to reduce operational costs and increase throughput. A step that can’t be overlooked in pursuit of those goals is the picking process, because the longer it takes to fulfill an order, the less profitable that order is. Show
Batch picking is an order picking methodology that, when implemented correctly, improves picking efficiency by grouping multiple similar orders into one pick instruction. What Is Batch Picking?Batch picking, also called batching or multi-order picking, is an order picking method in which pickers simultaneously collect items for multiple orders. Batch picking is generally faster than other picking strategies — such as single order picking, in which pickers tackle one order at a time — because it reduces warehouse travel time. Pickers report walking as many as 10 miles a day to perform their jobs, but batch picking eliminates the need to repeatedly revisit the same picking location multiple times in a shift as they fulfill orders, cutting travel time significantly. Batch vs. Wave PickingIn batch picking, a single picker picks a batch of orders at the same time. The goal is to create an optimal pick path that prevents pickers from visiting the same item location multiple times when fulfilling multiple orders. In wave picking, warehouse managers schedule picking windows — or waves — throughout the day. The goal Order are sent to fulfillment based on what is in them so that like orders can be filled together; it’s like a step beyond batch picking. Batch vs. Zone PickingZone picking is another popular way to increase order picking efficiency. In batch picking, a single picker usually will fulfill several orders in full. In zone picking, a single order is split among multiple pickers who pick different items within the order that are located in a similar area (or zone) in the warehouse. Each picker is assigned a zone in the warehouse and only picks SKUs from that zone. Once the picker collects the necessary SKUs from their batch, they might put it in a tote and pass it on to the next zone until the entire order is picked. Like batch picking, zone picking can increase picking efficiency by reducing travel time. However, zone picking does not require orders to be grouped together. This makes zone picking a better option for businesses that do not regularly deal with similar orders. But depending on a warehouse’s picking needs, zone picking may be combined with other picking strategies, like wave picking, batch picking or both. Batch Picking ExplainedBatches usually consist of about eight to 20 similar orders that are consolidated into a single pick list. Orders that are batched together generally have several of the same items or even extremely similar pick paths. To establish optimal batch grouping and pick routes, it’s important to use a warehouse management system (WMS) and order management system (OMS). The WMS and OMS can analyze orders and your specific warehouse layout to create pick plans that minimize travel time, resulting in more time spent picking and less time spent walking. Batch picking can be highly productive because workers are able to pick many SKUs for several orders in one trip, rather than making separate, repeated trips throughout the warehouse. Additionally, grouping picks means fewer people are moving through warehouse aisles at any one time. This leads to fewer bottlenecks, enabling workers to reach their destinations more quickly. Order need to then be sorted in the packing areas into their proper boxes. How Does Batch Picking Work?With a WMS or OMS in place to determine optimal batches and map picking routes, batch picking is a fairly straightforward process. Here’s how it works:
Benefits of Batch PickingFast, accurate picking is important not only to simplify order fulfillment operations, but to a business’s long-term success. When customers receive accurate orders quickly, they’re more likely to be satisfied and become loyal shoppers. Many warehouse operations can benefit from batch picking because:
Batch Picking ExamplesTo better understand the batch picking process, it can be helpful to consider an example. Imagine three customer orders that need to be picked: Customer A
Customer B
Customer C
Rather than pick each customer’s order individually before proceeding to the next, a warehouse worker using batch picking might first pick all 70 packages of AAA batteries for all customers and place them in a designated tote on a push cart. Next, the picker collects all 25 units of copper wire LED lights and places them in another tote on the same cart. Then the picker collects the five hand trowels for customer B and places them in another tote. Before picking the garden planters for customers A and B — which are large and cannot fit on the pushcart — the picker brings all the batteries, LED lights and trowels to the sorting area. Finally, the picker uses a pallet jack to collect all 22 garden planters on one pallet and brings it to the sorting area to be sorted and packed for shipping with the other goods. Batch Picking Case StudyBatch picking can significantly cut costs when implemented correctly. Take, for example, a fictional family pharmacy with a central warehouse that distributes items to its 50 retail stores in the Pacific Northwest. After the company opened 15 new locations, its distribution center struggled to keep up with demand. Given the company’s fairly small scale, it opted to reassess its order picking strategies before incorporating robotics and other automated processes. After some analysis, warehouse managers recognized that single order picking was no longer sustainable, especially because each retail location generally ordered the same types of items, so it switched to batch picking. For each shift, managers used their WMS to establish optimal order batches and picking routes that enabled workers to pick several orders at once, instead of repeatedly taking similar trips throughout the warehouse. Ultimately, the pharmacy was able to cut worker travel time by 55% and increase pick rate by 40%. And, despite the increase in demands, productivity gains enabled the company to reduce labor costs by 15%. Batch Picking and AutomationWhile batch picking can improve accuracy and speed on its own, automated systems that use robotic or semi-robotic modules can enhance picking capabilities and further optimize the picking process. Here are a few types of warehouse automation systems that can be applied to batch picking:
Optimize Batch Picking With TechnologyAs mentioned earlier, the benefits of batch picking can be further enhanced by using an OMS, WMS and inventory management tools. For example, an order management system can automatically manage an order’s life cycle, from the moment an order is placed to the time it’s delivered. The OMS can take that order data to automate order processing, thereby eliminating manual processes that can create bottlenecks and lead to human error, making it easier to fulfill orders quickly and accurately. Meanwhile, a warehouse management system can automatically manage all resources within the distribution center. A WMS can help companies keep track of warehouse organization, bin locations and inventory. It can also help prevent overstock and stockouts and be linked to warehouse technologies like barcode scanners, so pickers can easily confirm when they’ve picked orders. What’s more, a WMS can use data to better manage warehouse tasks, like creating optimal pick strategies based on typical order types and warehouse layout. Additionally, inventory management software can also improve order picking efficiency because it provides a real-time overview of inventory. This can be particularly useful in warehouses with fast-moving products that often need to be replenished. Any time spent waiting for SKUs to be replenished is time wasted and orders that take longer to ship. Inventory management tools can keep track of what products need to be restocked and when, so pickers never have to wait to fulfill orders. By enabling order pickers to pick multiple items for multiple orders at the same time, batch picking is one way for warehouses and distribution centers to efficiently fulfill orders. Combined with automation and software like a WMS or OMS, the order picking process can be further optimized and help businesses get orders to customers with greater speed and accuracy. Batch Picking FAQsWhat are the costs and benefits of batch picking?The cost of batch picking can vary based on picking system technology and complexity. Basic systems might use an order management system (OMS) to generate pick lists that appear on mobile picking devices. Others might take technology a step further to incorporate barcode scanners, pick-to-light systems or voice picking systems. The most elaborate — and generally most expensive — batch picking systems incorporate automation and robotics. What is the zone picking method?With zone picking, an order is split among multiple pickers who each pick different items within a single order. Each picker is assigned to a picking zone and only picks the SKUs within their zone. Zone picking lessens travel time and can prevent bottlenecks in aisles. Unlike batch picking, zone picking doesn’t require the same types of items to be ordered. However, it can be difficult to equitably distribute the workload because not all orders will require items from each zone. What is picking in a warehouse?Picking is the act of selecting products in preparation to be shipped. Employees called “pickers” locate, select and count the items needed to fulfill orders before delivering them to the packing and shipping area. There are several methodologies to streamline that process, including batch picking. How do you calculate order picking accuracy?Companies can calculate order picking accuracy by determining the number of orders that are picked in full and comparing them with orders that were short-picked, short-packed or mispicked. The formula is: Order picking accuracy = (Number of accurate orders picked / Total number of orders picked) x 100 |